Hollow Winding Core Separator Suction for Compact Battery Manufacturing
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Solution Overview
Problem
Existing methods for manufacturing small-size lithium ion secondary batteries are inefficient and lack a suitable manufacturing method and winding device to produce batteries with precise dimensions and high volumetric efficiency.
Innovation Solution
A method involving suctioning a strip-shaped separator through holes in a winding core with an outside diameter of 2 mm or less, winding positive and negative electrodes around the core, and releasing the suction to pull out the core, creating a cylindrical electrode body with a hollow center, accompanied by a winding device with a hollow core and peripheral holes for precise battery construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a conventional winding method is used, then the manufacturing process is simple, but the battery size cannot be reduced and volumetric efficiency is low
Solution Approach 1:
The invention uses a hollow winding core with multiple holes that allows the separator to be nested within the core structure during winding. The separator passes through the hollow center and peripheral holes of the core, creating a compact nested arrangement that reduces overall battery volume while maintaining structural integrity
Solution Approach 2:
The winding core is segmented with multiple holes (e.g., three holes at 120-degree intervals) instead of a solid structure. This segmentation allows the separator to be divided and positioned through different holes, enabling precise control of electrode spacing and achieving higher volumetric efficiency in the wound battery structure
2Length of moving object
If the winding core outside diameter is reduced to 2 mm or less, then the battery size is reduced, but the strength of the winding core may be compromised
Solution Approach 1:
The winding core has different structural properties at different locations: the hollow center provides flexibility and space for separator insertion, while the peripheral walls containing the holes provide structural strength. This local differentiation allows the core to be thin (2 mm or less diameter) while maintaining sufficient strength for the winding process
Solution Approach 2:
The winding core is made of a composite structure combining a hollow cylindrical body with integrated peripheral holes. This composite design optimizes the strength-to-weight ratio, allowing the core to maintain structural integrity at reduced dimensions (2 mm or less outside diameter) while performing multiple functions (support, separator guidance, suction)
3Manufacturing precision
If multiple holes are provided in the winding core for separator suction, then the separator positioning is improved, but the core structure becomes more complex
Solution Approach 1:
The peripheral holes in the winding core serve multiple functions simultaneously: they guide the separator during winding, provide suction paths for separator positioning, and maintain structural integrity of the thin-walled core. This multi-functionality reduces the need for additional separate components, simplifying the overall device while achieving precise separator positioning
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the production of small-size batteries with high roundness and reduced size, improving volumetric efficiency and winding properties while maintaining the strength of the winding core, suitable for portable and wearable devices.
Implementation Method 1
suctioning a part of a strip-shaped separator in a plurality of holes of a winding core
Data Source
AI summary
A method for manufacturing a battery is provided. The method includes suctioning a part of a strip-shaped separator in a plurality of holes of a winding core in a peripheral surface of the winding core; preparing a wound body by winding strip-shaped positive and negative electrodes along with the strip-shaped separator around the winding core; and preparing an electrode body by releasing the suction in the holes and pulling out the winding core from the wound body, in which the battery includes a battery container configured to accommodate the electrode body, the holes are communicated inside with the winging core having a hollow structure, and the winding core has an outside diameter of 2 mm or less.